Me8793 Ppce Unit IV

ME 8793 – PROCESS PLANNING
& COST ESTIMATION

UNIT – IV
PROUCTION COST
ESTIMATION
1 PREPARED BY
J. SRINIVAS. M.E.,
ASSISTANT PROFESSOR,
MECHANICAL ENGINEERING.
ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering
SYLLABUS
Estimation of Different Types of Jobs
Estimation of Forging Shop
Estimation of Welding Shop
Estimation of Foundry Shop
2
ESTIMATION OF DIFFERENT TYPES OF JOBS
There are many types of jobs done by using fabrication in which different
operations are performed to get desired jobs. The different types of operations
done are:
 Sheet metal works
 Forging
 Welding
 Foundry
SHEET METAL SHOP OPERATIONS

For working in sheet metal shop, an engineer must have a good
knowledge regarding plane geometry, mensuration, development of
surfaces etc., Sheet metal process is generally used for preparing bodies of
buses, cars, aeroplanes, boiler shells, chimneys, pipes, boxes, toys, 3
furniture making, refrigeration & air conditioning body etc.,

Most sheet metals are steel rolled into sheets of various thickness & then
coated with zinc, tin or lead. Other common sheet metals & alloys are zinc,
copper, aluminium & stainless steel.
Gauge
10 12 14 16 18 20 22 24 26 28 30
Number
Thickness in
3.25 2.64 2.03 1.62 1.22 0.99 0.71 0.56 0.45 0.36 0.35
mm
Following are the important operations & processes carried out in sheet
metal shop:
Breaking Out – Folds or ribs in sheets, are removed either with the help of
beating the sheets or by passing the sheets through rollers.
Bending – Bending is carried out for making cylindrical shapes from sheets.
Length of Bending = 2 r x θ/360
r – radius of bend, θ – angle subtended by bend through centre. 4
Turning up – for making sharp bends to sheets for seaming, hemming etc.,
Hollowing – process of beating the metal for giving it concave shape
Allowance for Hollowing = ½ (base)2 + (height)2
Raising – process of beating the metal over the spherical head to give a convex
shape.
Allowance for Raising = ½ (base)2 + (height)2
Planishing – gives the final finish to the hollow or raised surfaces by removing
minor bends by beating the sheet with the help of Planishing hammer.
Edge Stiffening – to give a product with finished appearance.
 Wiring – Allowance = 2.5 x D + 4 x t
(D – Diameter of wire & t – sheet thickness)

 False wiring – same as above
 Hemming – Allowance = 4.5 times the sheet thickness

5
 Flanging – folded at an angle of 90 to give the shape of flange.
o
SHEET METAL JOINTS
 Lap joint
 Single seam joint – Allowance = 5 t
 Double seam joint – Allowance = 8 t
 Grooved joint – Allowance = 10 t
 Single plate butt joint – Width = 10 t
 Dovetail joint – Length = 12 to 20 t & Width = 4.5 t
 Riveted joint – Diameter of Rivet D = 1.92 √ t
Minimum distance between first rivet centre & 6
sheet edge = 1.5 D & Pitch (p) = 3 D

Cost of sheet metal = ₹4/kg, Welding Material Cost = ₹5/metre
7
of weld
SHEET METAL PROBLEM

Sheet required = 4 x 1 x 0.5 + 0.5 x 0.5 = 2.25 m2
Scrap (5%) = 5 x 2.25/100 = 0.1125 m2
Actual Sheet required for container = 2.25 + 0.1125 = 2.3625 m2
Volume of the sheet = 2.36 x 0.006 m3
Weight of the sheet = Volume of sheet x Density of sheet
= 2.36 x 0.006 x 8 x 1000 = 113 Kg (1g/cc = 1000 kg/m3)
Cost of sheet @ ₹4/kg = 113 kg x ₹4/kg = ₹ 452
Welding Material Cost @ ₹5/metre of weld = ₹5 x (1x4+0.5x4) = ₹ 30
Total Material Cost = Sheet Cost + Welding Material Cost = 452 + 30 = ₹482
Labour cost @10% of Material Cost = 482 x 0.1 = ₹ 48.2
Total Cost of container = Total Material Cost + Labour Cost
Total Cost of container = 482 + 48.2 8
Total Cost of container = ₹ 530.2

ESTIMATION OF FORGING SHOP

Forging is the process in which the metal is heated at sufficiently
high temperature to bring it to the plastic state.
Forging Types:
 Hand Forging
 Machine Forging
 Smith forging
 Drop Forging
 Press Forging
Forging Operations
 Drawing Down
 Up Setting
 Bending
9
 Punching and Drafting
 Swaging

Drawing Down: It is also known as Drawing Out. This operation is performed
to increase the length of the workpiece in forging by decreasing the cross-
sectional area. This process is performed by hammering the hot workpiece
lengthwise to reduce cross-section.
Up Setting: This is the reverse of Drawing Down operation. In this operation,
the cross-section of workpiece is increased at the expense of length. This process
is performed by hammering one end of hot workpiece while other end is
supported against the anvil.
Bending: Bending is done by holding the workpiece between two fixtures and
desired bend can be given by striking the workpiece with the help of hammer.
This operation can also be carried out on the anvil break.
Punching and Drafting: Punching operation is performed by a tool called
punch, for producing holes in the workpiece, when it is in the hot state; and
drafting is an operation carried on by a special tool known as draft to enlarge10
the hole.

Swaging is a forging process in which the dimensions of an item are altered
using dies into which the item is forced.
Forging Estimation Procedure
Estimation procedure varies from shop to shop and person to person but
for a general procedure, following factors may be considered:
For estimation of net weight of the forged component, following procedure
is adopted:
a. Break up the job drawing into suitable geometrical section, whose volumes
can easily be calculated by using mensuration.
b. Next, find the value of each section, neglecting rounded corners and taking
suitable assumptions.
c. Now, find total volume of material required by subtracting volume of the
hollow spaces. 11
d. Lastly, calculate the weight of the component by multiplying the total volume
with its density.

Estimation of Losses
Certain amount of material is lost during different forging operations.
The exact estimation of losses is very difficult, but by practical experience, the
losses can be calculated during forging as accurate as possible. Various losses in
forging are:
 Tong Loss: While performing forging operations, some length of stock is
required for holding the job in tong. This length is an extra length, which is
removed after completion of the job. For estimation purposes, the weight of
the extra length is also considered and is known as Tong loss. 2 to 3 cm of the
stock length.
 Scale Loss: The outer surface of the hot metal is generally oxidized, and
when hammering is done oxidized film is broken and falls down in the form of
scale. It reduces the dimensions of the job, and therefore, this loss must be
considered for estimation purposes. Generally, it is taken as 6% of the net 12
weight.

Estimation of Losses
 Flash Loss: It is the surplus metal, which comes out between the two meeting
surfaces of the dies. For getting finished product, this surplus metal is
required to be trimmed off. This loss may be calculated by assuming it to be
20mm wide and 3mm thick all around the periphery of the dies.
Thus, volume of flash loss = periphery x 20 x 3 mm3 nearly.
 Shear Loss: The required sizes of workpiece for forging operations are
obtained from long bars by sawing or shearing. In sawing operation, some
material is always lost. If last piece of bar is not to be required length, it is
rejected. This loss of material is taken as 5% of the net weight.
 Sprue Loss: The portion of metal between the length held in the tong and the
material in the die is called Sprue. This is also a metal loss and can be taken
as 7% of the weight.
13
Thus we can see that nearly 15-20% of the net weight of metal is lost
during forging.
FORGING COST CALCULATION
Calculation of Forging cost involves the following steps:
 Calculate the Net weight of the forging
 Calculate the various forging losses
 Calculate the gross weight = Net weight + Forging losses
 Calculate the diameter & length of the stock
Length of the stock = Gross weight / (Area of stock x Density of Material)

 Calculate the time required for forging, which includes heating of the stock
to the required temperature & different forging operations
 Calculate the labour cost
 Total cost of forging = Material Cost + Labour Cost + Overheads
(Material cost calculated on the basis of gross weight)

14
15
APRIL/ MAY 2017
FORGING SHOP PROBLEMS

Given: ρ = 7.86 g/cc, loss = 25% of net weight, Material cost = ₹80/kg,
Labour cost = ₹5/ piece, Overheads = 150% of Labour Cost.
To find: (i) Total Length required to forge one component if D = 14 mm
(ii) Total Cost of Forging
For Φ 40 section, Volume V1 = x D2 x L/4 = x 402 x 20/4 = 25132.7 mm3
Length of Φ 14 bar to forge Φ 40 section L1 = Volume of Φ 40 section/Area of bar
L1 = V1 / A = 25132.7/ ( x 142/4) = 163.25 mm
L2 = V2 / A = 17671.45/ ( x 142/4) = 114.796 mm
16
L3= V3 / A = 6283.185/ ( x 142/4) = 40.816 mm

Total length required to forge one component L = L1 + L2 + L3 + 50
L = 163.265 + 114.796 + 40.816 + 50 L = 368.89 mm
Volume of the Component V = V1 + V2 + V3 + ( x 142 x 50/4)
V = 25132.7 + 17671.45 + 6283.185 + 7696.902
V = 56784.237 mm3 = 56.784 cm3
Weight of the material required = Volume x Density = 56.784 x 7.86
Net Weight of the material required = 446.324 g.
Gross weight of Material required = Net Weight + Losses
Gross weight of Material required = 446.324 + 446.324 x 25/100 = 557.905 g
Materials Cost = 80 x 0.557905 = ₹44.63, Labour Cost = ₹ 5/ piece
Overheads = 5 x 150/100 = ₹7.5
Total cost of Forging/Piece = Materials Cost + Labour Cost + Overheads
17
Total cost of Forging/Piece = 44.63 + 5 + 7.5
Total cost of Forging/Piece = ₹ 57.13 per Piece
18
NOV/ DEC2016 14 (a)
Given: N = 200, Material Cost = ₹1000 / metre, Forging charges = ₹10 / cm2,
On – cost = 10% of M Material Cost To Find: Cost of Manufacture
Volume of the Component = ( x 42 x 5/4) + ( x 32 x 4/4) + (2 x 2 x 2) = 99.06 cm3
Consider the various losses in drop forging:
Scale Loss = 6% of volume = 0.06 x 99.06 = 5.98 cm3
Shear Loss, 2 mm Length in cutting one piece from long bar stock = 0.2 x x42/4
Shear Loss = 2.512 cm3
Flash Loss, assuming width = 2 cm & thickness as 0.3 cm
Flash Loss = Periphery of parting line of dies x 2 x 0.3
Flash Loss = (5+0.5+4+0.5+2+2+2+0.5+4+0.5+5+4) x 2 x 0.3 = 18 cm3
Tong Loss, taking 2 cm extra length required for the use of Tong
Tong Loss = 2 x x42/4 = 25.12 cm3 19
Sprue Loss = 5% of volume = 0.05 x 99.06 = 4.98 cm3


Gross Volume per Piece = Net Volume + Losses
Gross Volume per Piece = 99.06 + 5.98 + 2.51 + 18 + 25.12 + 4.98 = 155.65 cm3
Volume required for 200 pieces = 200 x 155.65 = 31130 cm3
Length of bar stock required = 31130/ ( x42/4) = 2478 cm = 24.78 m
Material Cost = 24.78 x 1000 = ₹24780
Forging Charges = ₹ 10 x Surface Area
Forging Charges = 10 x {( x42/4) + x 4 x 5 + [ x (42 - 32)/4] + [( x32/4) – 2 x 2]
+ x 3 x 4 + 4 x 2 x 2 + 2 x 2} = ₹ 980
Forging Charges for 200 pieces = 200 x 980 = ₹196000
Now, On – cost = 10% of Material cost = 0.1 x 24780 = ₹2478
Manufacturing Cost = Material Cost + Forging charges + On – Cost
Manufacturing Cost = 24780 + 196000 + 2478 20
Manufacturing Cost = ₹ 223258
21
All Dimensions are in mm

Given: N = 300, Scrap = 4% of the Length, Bar Stock Dia = 25 mm
To Find: Length of Each Bolt before Upsetting, Total L including Scrap
Volume of the head of the bolt = ( x 402 x 22/4) = 27646 mm3

Length required for making bolt head = Volume of Bolt head/Area of Bar
Length required for making bolt head = 27646/ ( x 252/4) = 56.35 mm
Total Length required for making one bolt = 56.35 + 113
Length of Each Bolt before Upsetting = 169.35 mm
Length of rod for making 300 bolts = 169.35 x 300/1000 = 50.8 m

Considering 4% of the length as scrap,
22
Total length of making 300 bolts including scrap = 50.8 + 0.4 x 50.8
Total Length required including Scrap = 71.12 m
23
24
25
26
200 MS pins of 4 cm diameter and l0 cm length are to be drop forged
from a bar of 5 cm diameter. Calcu1ate material cost taking the cost of
stock as ₹ 200 per meter. Consider all the losses. Also calculate the
forging cost assuming the cost of forging as ₹ 1200/m2 of surface area.
Given: MS Pins N = 200, L = 10 cm of D = 4 cm, Bar Stock Dia = 5 cm, Material
Cost = ₹200/m, Cost of Forging = ₹ 1200/m2 of Surface Area.
To Find: Length of Each Bolt before Upsetting, Total L including Scrap
Volume of the pin = ( x 42 x 10/4) = 125.6 cm3
Consider the various losses in drop forging:
Scale Loss = 6% of volume = 0.06 x 125.6 = 7.536 cm3
Shear Loss, 2 mm Length in cutting one piece from long bar stock = 0.2 x x52/4
Shear Loss = 3.925 cm3
27
Flash Loss = Periphery of parting line of dies x 2 x 0.3
Flash Loss = (4+10+4+10) x 2 x 0.3 = 16.8 cm3

Tong Loss, taking 2 cm extra length required for the use of Tong
Tong Loss = 2 x x52/4 = 39.25 cm3
Sprue Loss = 5% of volume = 0.05 x 125.6 = 6.28 cm3
Gross Volume per Piece = Net Volume + Losses
Gross Volume per Piece = 125.6+7.536+3.925+16.8+39.25+6.28 = 199.39 cm3
Volume required for 200 pieces = 200 x 199.39 = 39878.2 cm3
Length of bar stock required = 39878.2/ ( x52/4) = 2031 cm = 20.31 m
Material Cost = 20.31 x 200 = ₹4062
Forging Charges = ₹ 1200 x Surface Area
Forging Charges = 1200 x {( x42/4) + x 4 x 10 +( x42/4)} =1200 x 0.0151
Forging Charges = ₹ 18.12/Piece
Forging Charges for 200 pieces = 200 x 18.12 = ₹3624
28
Forging Cost = Material Cost + Forging charges = 4062 + 3624
Forging Cost = ₹ 7686

150 pieces of shafts as shown in fig. are to be drop forged from the
raw stock of 2 cm diameter. Estimate the cost incurred, assuming the
material cost is ₹52/m, cost of forging is ₹250/m2 of surface area to be
forged and overhead charges to be 100% of the cost of the forging.
Consider all losses.
29
Volume of the Component = 5.06582 x 10-5 m3
Scale Loss = 3.0396x 10-5 m3, Shear Loss = 2.533 x 10-5 m3
Flash Loss = 3.57 x 10-5 m3, Tong Loss = 6.283 x 10-6 m3
Sprue Loss = 3.5462x 10-5 m3, Total Loss = 1.33171x 10-4 m3
Gross Volume = 1.8383 x 10-4 m3 /Piece,
For 150 pieces Total Volume = 0.027575 m3
Length of Bar = 87.77 m,
Cost of Material = ₹ 4564
Surface Area = 0.012959 m2
Forging Charge/Piece = ₹ 3.24,
Total Forging Charges = ₹ 486  Overheads = ₹ 486
Total Cost Incurred = ₹ 5536 30
ESTIMATION OF WELDING SHOP

Welding is the process of joining two or more metal pieces by
heating them upto the desired temperature with or without the
application of pressure and with or without the use of filler metal.
Welding Types Welding Types
 Butt Weld Joints  Fillet Weld Joint
 Square Butt Weld  Lap Joint
 Vee Butt Weld  Tee Joint
 Single Vee Butt Weld  Corner Joint
 Double Vee Butt Weld  Edge Joint
 Bevel Butt Weld  Strap Joint
 Single Bevel Butt Weld
 Double Bevel Butt Weld

31

ELECTRIC WELDING (ARC WELDING)
Arc welding is done by producing an arc between the work to be welded
and the tip of the electrode. A high voltage is necessary for an arc to strike &
than to maintain it because some of the voltage goes for ionizing the air gap.
For estimating the cost of arc welding, following costs are included:
 Material cost – includes the cost of electrodes
 Labour cost
 Power charges
 Finishing cost including post weld treatment cost
 On – cost
32

Factors affecting welding cost
 Time required for handling & settling the job and equipment in correct
position
 Time required for fixing the fixtures
 Rest and fatigue time allowance – 5 to 10% of the total time
 Excessive welding – increases the cost of welding
 When excessive current is used, welding cost also increases.
Plate Power
Electrode Length of electrode Welding time in
Thickness consumption per
no. required in m of welding min/m
in mm m length in KWh
3 10 0.50 – 0.60 6–7 1.2
5 8 0.70 – 0.80 10 – 12 2.0
10 6 1.00 – 1.20 20 – 25 3.0
33
15 6 1.75 – 2.00 35 – 40 3.7
20 4 2.00 – 2.60 40 – 45 4.8
34
Assume for 6 mm thickness, Power Consumption = 2.2 KWh/m and Power Charges as ₹ 5/KWh
WELDING SHOP PROBLEMS
Volume of Container = 50 x 50 x 100 = 250000 cm3
Weight of Container = 250000 x 8 = 2000000 g or 2000 Kg
Actual weight of sheet metal plate = 2000 + 0.05 x 2000 = 2100 Kg
Length of the welding area = 11’+12+1’2’+22’+14+23+2’3’+1’4’
Length of the welding area = 0.5+0.5+0.5+0.5+1+1+1+1 = 6 m
Cost of welding material = 6 x 20 = ₹ 120
Cost of sheet metal plate = 2100 x 10 = ₹ 21000
Cost of Labour = 10% of sheet metal cost = 0.1 x 21000 = ₹ 2100
Power Consumption = 2.2 x 6 = 13.2 KWh
Power Charges = 13.2 x 5 = ₹ 66
Total Cost of the container = Cost of welding material + Cost of sheet metal
plate + Cost of Labour + Power Charges = 120 + 21000 + 2100 + 66 35
 Total Cost of the container = ₹ 23286

36

Labour Charges:
Total length of weld on outer side = Length of weld on inner side
Total length of weld on outer side = 2 x x 1 + 3 = 9.283 m
Labour Charges: Time Required for Welding 9.283 m is
On outer side = 9.283 / 4 = 2.321 hours; On inner side = 9.283/3 = 3.094 hour
Total time required = 2.321 + 3.094 = 5.415 hours
Considering charges for welding setting time,
@7% of welding time = 5.415 x 1.07 = 5.794 hours
Actual Labour charges @ ₹100/hour = 5.794 x 100 = ₹ 579.41
Cost of Electrodes:
Length of electrode required @1.8m/m of welding = 1.8 x 2 x 9.283 = 33.42 m
37
For 6% discarded electrodes, Electrodes assumed = 33.42 x 1.06 = 35.425 m
Cost of Electrodes @ ₹12/m = 32.425 x 12 = ₹ 425.10
Power Charges:
Power P = VA = 40 x 325 = 13000 VA = 13 KVA, Power factor = 0.85
Power P = 13 x 0.85 = 11.05 KWh or 11.05 Unit
Power Charges @₹7/ unit = 11.05 x 7 = ₹ 77.35
Prime Cost = Labour Cost + Cost of Electrodes

Prime Cost = 579.41 + 425.10
Prime Cost = ₹ 1004.51
Overheads = 100 % of Prime Cost = ₹ 1004.51
Total Welding Cost = Prime Cost + Overheads + Power Charges

Total Welding Cost =1004.51 + 1004.51 + 77.35 38
Total Welding Cost = ₹ 2086.37

Length of Weld on outer side = 8.78 m = Length of weld on inner side = Length of welding on
circular plates + length for welding seam joint. Total Time required = 3.51 + 4.39 = 7.90 hours
Labour Charges = ₹ 31.60 & Actual Labour Charges considering Allowances = ₹ 33.50
Length of electrodes required = 1.5 x 2 x 8.78 = 26.34 m, With discarded electrodes, L = 27.66 m
Cost of Electrodes = ₹16.60
Power Consumption = 4 x 2 x 8.78 = 70.24 KWh, Power Charges = 70.24 x 3 = ₹ 210.72
Prime Cost = Labour charges + Cost of Electrodes = 33.50 + 16.60 = ₹ 50.1
Overheads = 2 x 50.1 = ₹ 100.2 39
Total Welding Cost = Prime cost + Overheads + Power charges = 50.1 + 100.2 + 210.72
Total Welding Cost = ₹ 361.02.

Two 1 m long MS plates of 10 mm thickness are to be welded by a lap
joint with a 6 mm electrode. Calculate the cost of welding. Assume the
following data: Current used = 250 A, Voltage = 30 V, Welding speed =
10 m/hr, Electrode used = 0.1 Kg/m of welding, labour charges = ₹2 /hr,
Power charges = ₹0.20/ KWh, Cost of electrode = ₹35 / kg and Efficiency
of the machine = 60%.
Electrode required for 1 m length of welding = 0.1 kg
Cost of electrode @ ₹35 / kg = 35 x 0.1 = ₹ 3.5
Time required for welding 1 m length = 1/10 hr, Labour cost = 2 x 1/10 = ₹ 0.20
Power = V x I/ Efficiency = 250 x 30/0.6 = 12.5 KW
Energy consumed for welding 1 m length = 12.5 x 1/10 = 1.25 KWh
Power Charges @ ₹0.20/KWh = 1.25 x 0.20 = ₹ 0.25
Total welding cost = Cost of electrodes + Labour charges + Power charges
40
Total welding cost = 3.5 + 0.20 +0.25
Total welding cost = ₹ 3.95
A lap joint is to be prepared from 9.5 mm mild steel using flat
welding position and 6 mm electrode. Current used is 250A and voltage
30 V, welding speed is 12m/hr and 0.34 kg of metal is deposited per
metre length of joints. Labour cost = ₹2.5/hr, power = ₹0.2/KWh and
electrode ₹40/kg. Efficiency of the machine is 50% and operation factor
is 60%. Calculate the cost of labour, power and electrode per metre of
weld.
Cost of Electrode/metre of weld = ₹ 13.6
Labour Cost/metre of weld = ₹ 0.347
Cost of Power / Metre of weld = ₹ 0.25
41
GAS WELDING

In gas welding, gas flame is used for heating and melting the joining
surfaces and the filler rod. Gas welding is done by burning a combustible gas
with air or oxygen in a concentrated flame of high temperature. Most important
combustible gas which gives highest temperature is Acetylene.
Acetylene C2H2 – 92.3 % C & 7.7% H2 by weight, Temperature of
oxyacetylene flame – 32000 C to weld the steel. In case of gas welding, two
welding techniques are adopted in practice: Leftward or Fore – hand welding
& Rightward or Back – hand welding.
Left ward welding is started from right hand side of the joint and
proceeds towards the left hand side. This method is suitable for welding
plates upto 3 mm thickness without edge preparation and upto 5 mm thickness
with edge preparation.
Right ward welding is started from left hand side of the joint and
proceed towards the right hand side. This method is suitable for steel plates
42
which are of more than 5 mm thickness. Edge preparation is not required beyond
8 mm thickness plates should be bevelled to about 300.
Gas welding can only be done on plates upto 25 mm thickness. The table is useful in estimating

the welding cost in case of gas welding.
Gas Welding Cost = Preparation Cost + Material Cost + Labour Cost + Welding Finishing
Cost + On – cost.
Plate Welding Filler O2 Acetylene Welding Length of filler
thickness Technique rod Dia consumption consumption Time per rod required / m
in mm in mm in m3/hr in m3/hr metre in of welding in
min metre
1 Leftward 1.0 0.04 0.02 9 to 11 1.0
2 Leftward 2.0 0.10 0.04 10 to 12 1.5
3 Leftward 2.5 0.12 0.07 12 to 13 1.6
4 Leftward 3.0 0.15 0.10 13 to 15 2.6
5 Leftward 3–4 0.21 0.14 15 to 17 4.0 or 4.8
5 Rightward 2.5 0.3 0.20 16 to 18 3.3
6 Rightward 3.0 0.4 0.25 18 to 20 3.4
8 Rightward 4.0 0.5 0.30 20 to 28 3.6
10 Rightward 5.0 0.7 0.50 30 to 35 4.5
15 Rightward 6.0 1.0 0.60 45 to 50 6.8
43
20 Rightward 6.0 1.2 0.80 60 to 67 10.0
25 Rightward 6.0 1.6 0.90 85 to 100 16.0
44
45
46
47
FOUNDRY SHOP
Casting is a process in which molten metal is poured into a cavity,
known as Mould, of the desired shape formed by a pattern, and allowed
to solidify.
Foundry consists of
 Pattern Making section
 Melting & Pouring section
 Moulding & Core making section
 Fettling & heat treatment section
Pattern is a model of the product to be casted. The important

allowances which should be considered while making pattern:
 Contraction or Shrinkage allowance
 Machining allowance
48
 Draft allowance
Pattern cost = Direct Materials cost + Direct Labour cost + Overheads

FOUNDRY SHOP PROBLEMS
Foundry cost = Materials cost + Labour cost + Overheads / On – Costs
Estimate the power cost for melting Aluminium of 150 kg at 6500 C from
room temperature of 350 C. Specific heat and latent heat of aluminium
are 0.91 KJ/kg and 398 KJ/kg respectively. Unit cost of power is ₹7.
Q1 = m Cp (T2 – T1) = 150 x 0.91 x (650 – 35) = 83947.5 KJ
Q2 = m (LH) = 150 x 398 = 59700 KJ
Q = Q1 + Q2 = 83947.5 + 59700
Q = 143647.5 KJ
(1 Joule = 2.8 x 10– 7 KWh)  143647.5 x 103 J = 143647500 x 2.8 x 10– 7
Power = 39.93 KWh
Power Cost = 39.93 x 7
49
Power Cost = ₹ 280 (Approx)
50
APRIL/MAY 2018, 14 (a)
{Q = m (LH) = 1000 x 272 = 272000 KJ – Additional Data Given}
Materials Cost = ₹ 38/kg x 1000 kg = ₹ 38000
Total working hours of furnace = 24 x 300 = 72000 hours
Labour cost = ₹ 20000/month = ₹240000/year
Power = 750 KVA, Power factor = 0.95
Power = 750 x 0.95 = 712.5 KWh = 712.5 Units
Power Cost = 712.5 x 6 = ₹4275.45/month = ₹4275.45 x 12 = ₹ 51305.48 /Year
Total Cost for Melting CI/kg = (Furnace cost + labour cost+ Miscellaneous Exp +
Materials Cost + Maintenance Cost+ Power Cost)/ m
Total Cost for Melting CI/kg = (6000000 + 240000+ 70000 + 38000 + 200000 +
51305.48)/ 1000 = 6599305.48 / 1000
Total Cost for Melting CI/kg = ₹ 6599.305 51
52
NOV/DEC 2018
Volume of the component = 2 x volume of the leg + volume of the arc
Volume of the component = 2 x (6x2x6) + x (7.52 – 62) x 6/2 = 335 cm3
Net weight of the casting = 335 x 7.2 = 2412 g = 2.412 kg
Process scrap = 2.412 x 0.17 = 0.4 kg
Total Material / piece = 2.4 + 0.4 = 2.8 kg
Material cost/ piece = 2.8 x 30 = ₹ 84
Process return = 0.4 x 5 = ₹ 2
Net Material Cost per Piece = 84 – 2 = ₹ 82
Labour charges / piece = Moulding & Pouring + Casting removal, Gate cutting
etc + Fettling & Inspection = 10 x 30/60 + 4 x 10/60 + 6 x 10/60
Labour charges / piece = 5 + 0.67 + 1 = ₹ 6.67/piece
Shop overheads/piece = 10 x 30/60 + 4 x 30/60 + 6 x 30/60 = 5+2+3 = ₹ 10/piece53
Administrative Overheads = 2 x 2.8 = ₹ 5.6
Total Cost per Piece = Net Material Cost + Labour Charges + Shop Overheads +
Administrative Overheads
Total Cost per Piece = 82 + 6.67 + 10 + 5.6
Total Cost per Piece = ₹ 104.27
54

Me8793 Ppce Unit IV

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ME 8793 – PROCESS PLANNING

& COST ESTIMATION

SHEET METAL SHOP OPERATIONS

furniture making, refrigeration & air conditioning body etc.,

(D – Diameter of wire & t – sheet thickness)

 Hemming – Allowance = 4.5 times the sheet thickness

sheet edge = 1.5 D & Pitch (p) = 3 D

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

Total Cost of container = ₹ 530.2

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

 Calculate the various forging losses

 Calculate the gross weight = Net weight + Forging losses

 Calculate the diameter & length of the stock

Length of the stock = Gross weight / (Area of stock x Density of Material)

 Total cost of forging = Material Cost + Labour Cost + Overheads

(Material cost calculated on the basis of gross weight)

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

Sprue Loss = 5% of volume = 0.05 x 99.06 = 4.98 cm3

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

All Dimensions are in mm

Volume of the head of the bolt = ( x 402 x 22/4) = 27646 mm3

Length of rod for making 300 bolts = 169.35 x 300/1000 = 50.8 m

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

 Double Bevel Butt Weld

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

 Finishing cost including post weld treatment cost

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

 Rest and fatigue time allowance – 5 to 10% of the total time

 Excessive welding – increases the cost of welding

 When excessive current is used, welding cost also increases.

 Total Cost of the container = ₹ 23286

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

Prime Cost = Labour Cost + Cost of Electrodes

Total Welding Cost = Prime Cost + Overheads + Power Charges

Total Welding Cost = ₹ 2086.37

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

ME8793_PPCE_Prepared By J. SRINIVAS., ME., Assistant Professor/Mechanical Engineering

 Melting & Pouring section

 Moulding & Core making section

 Fettling & heat treatment section

Pattern is a model of the product to be casted. The important

Pattern cost = Direct Materials cost + Direct Labour cost + Overheads

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